Marshall Mix Design-Good

9/28/2019 Marshall Mix Design
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Mix Design Method:
The objective of Mix Design Method is to determine the amount of

various sizes of mineral aggregates to use to get a mix of maximum
density or, determines the optimum bitumen content. Two (02) types
of mix design are used in the world, these are,
——Dry Mix Design,
——Wet Mix Design,
Dry Mix Design: Dry Mix Design Method is used to determine the
amount of various sizes of mineral aggregates to use to get a mix of
maximum density. The Dry Mix Design involves three important steps
https://civilengineer365.com/marshall-mix-design/ 1/11
known as,
—selection of aggregates,
—aggregates gradation,
—proportion of aggregates,
which are discussed below,
Selection of Aggregates:
The desirable qualities of a bituminous paving mixture are

dependent to a considerable degree on the nature of the aggregates
used. Aggregates are classi ed as coarse, ne and ller. The function
of the coarse aggregates in contributing to the stability of a
bituminous paving mixture is largely due to interlocking and frictional
resistance of adjacent particles. Similarly, nes or sand contributes to
stability failure function in lling the voids between coarse
aggregates. Mineral ller is largely visualized as a void lling agent.
Crushed aggregates and sharp sands produce higher stability of the
mix when compared with gravel and rounded sands.
Aggregates Gradation:
The properties of the bituminous mix including the density and

stability are very much dependent on the aggregates and their grain
size distribution. Gradation has a profound e ect on mix
performance. It might be reasonable to believe that the best
gradation is one that produces maximum density. This would involve
a particle arrangement where smaller particles are packed between
larger particles, thus reducing the void space between particles. This
create more particle-to-particle contact, which in bituminous
pavements would increase stability and reduce water in ltration.
However, some minimum amount of void space is necessary to,
——Provide adequate volume for the binder to occupy,

——Promote rapid drainage and
——Provide resistance to frost action for base and sub base courses.
A dense mixture may be obtained when this particle size distribution

follows Fuller Law. Fuller’s model (Asphalt Institute 1992) represents
the equations of coarse and ne aggregates gradation.
For Fine Aggregates, Fuller’s Law can be expressed as follows,
Pi = 100(Di/D max) n
where,
Di = sieve size (diameter in mm),
D max = maximum aggregates size (mm),
n = shape factor of the aggregates (0.5 for perfectly rounded
particles),
Pi = amount ner than diameter Di ,
i = sub-index which represents a particular sieve,
For Coarse Aggregates, Fuller’s Law can be expressed as follows,
Pi = A*(Di/D max)nC * 100 + B

where,
A & B are constant,
nC = coe cient of coarse aggregate gradation,
Proportioning of Aggregates:
After selecting the aggregates and their gradation, proportioning of

aggregates has to be done and following are the common methods
of proportioning of aggregates:
—Trial and Error Procedure: Vary the proportion of materials until

the required aggregate gradation is achieved.
—Graphical Method: Two Graphical Methods in common use for
proportioning of aggregates are, Triangular Chart Method and Roch’s
Method. The former is used when only three materials are to be
mixed.
—Analytical Method: In this method a system of equations are
developed based on the gradation of each aggregates, required
gradation and solved by numerical methods.
Wet Mix Design:
The Wet Mix Design determines the Optimum Bitumen Content.

There are many methods available for Wet Mix Design which vary in
the size of the test specimen, compaction and other test
speci cations. Marshall Method of Mix Design is the most popular
one and is discussed below,
Marshall Mix Design:
The basic concepts of the Marshall Mix Design method were

originally developed by Bruce Marshall of the Mississippi Highway
department around 1939 and then re ned by the U.S. army. The
Marshall method seeks to select the asphalt binder content at a

desired density that satis es minimum stability and range of ow
values.
This section consists of a brief history of the Marshall Mix design
method followed by a general outline of the actual method. This
outline emphasizes general concepts and rationale over speci c
procedures.
Marshall Method history:
During World War II, the U.S Army Crops of Engineers (USCOE) began
evaluating various Hot Mix Asphalt (HMA) Mix Design Methods for
use in air eld pavement design. Most for this search came from the
ever-increasing wheel loads and tire pressures produced by larger
and larger military aircraft.
The most promising method eventually proved to be the Marshall
Stability method developed by Bruce G. Marshall at the Mississippi
Highway Department in 1939. U.S Army Waterways Experiment
Station (WES) took the original Marshall Stability Test and added a
deformation measurement (using a ow meter) that was reasoned to
assist in detecting excessively high asphalt contents. This appended
test was eventually recommended for adoption by the U.S. Army
because,
1. It was designed to stress the entire sample rather than just a
portion of it,
2. It facilitated rapid testing with minimal e ort,
3. It was compact, light and portable,
4. It produced densities reasonably close to eld densities,
WES continued to re ne the Marshall Method through the 1950’s with

various test on materials, tra c loading, and weather variables.
Today the Marshall Method, despite its shortcomings, is probably the
most widely used Mix Design Method in the world. It has probably
become so widely used because it was adopted and used by the U.S.
Military all over the world during and after WW II, it is simple,
compact and inexpensive.
Marshall Mix Design Procedure:
The Marshall Mix Design Method consists of 6 basic steps:

1. Aggregates Selection,
2. Asphalt Selection,
3. Sample Preparation (including compaction),
4. Stability Determination using the Stabilometer,
5. Density and Voids Calculations,

6. Optimum asphalt binder content selection.
Classi cation of Bitumen:
Classi cation of Bitumen can be speci ed as follows at Figure-01,
Figure-01: Classi cation of Bitumen
Liquid Asphalt is commonly used over the Existing Road Level, Liquid
Asphalt can be classi ed as follows,
a) Cutback Asphalt,
b) Emulsi ed Asphalt.
Cutback Asphalt:
When volatile solvents are mixed with asphalt cement to make a

liquid product, the mixture is called “Cutback Asphalt”. When a
Cutback Asphalt are exposed to air, the volatile solvent evaporates
and the asphalt in the mixture regain its original characteristics.
depending on the volatility of the solvent used, the rate of curing of
cutback asphalt can vary from a few minutes to several days. Three
type of cutback asphalts are,
a) Slow-Curing (SC): Road Oils,
b) Medium-curing (MC): Kerosene,
c) Rapid-curing (RC): Gasoline.
Emulsi ed Asphalt:
A mixture of asphalt cement, water and an emulsifying agent.

Two types of emulsi ed are,
a) Anionic Emulsion (AI): Anionic Emulsion are e ective in coating
electro-positive aggregates like limestone and Anionic Emulsion can
carry negative charges.
b) Cationic Emulsion (CIs): Cationic Emulsion are e ective in coating

electro-negative aggregates like siliceous and Cationic Emulsion can
carry positive charges.
————The Marshall stability and ow test provides the

performance prediction measure for the Marshall Mix Design
Method. The stability portion of the test measures the maximum load
supported by the test specimen at a loading rate of 50.8 mm/minute.
Load is applied to the specimen till failure and the maximum load is
designated as stability. During the loading, an attached dial gauge
measures the specimen’s plastic ow (deformation) due to the
loading. The ow value is recorded in 0.25 mm (0.01 inch) increments
at the same time when the maximum load is recorded. The important
steps involved in Marshall Mix Design are summarized next,
Specimen Preparation:
Approximately 1200 gm of aggregates and ller is heated to a

temperature of 121~125 degree C with the rst trial percentage of
bitumen (say 3.5 or 4% by weight of the mineral aggregates). The
heated aggregates and bitumen are thoroughly mixed at a
temperature of 154~160 degree C. The mix is placed in a preheated
mold and compacted by a hammer with 50 blows on either side at
temperature of 138~149 degree C. The weight of mixed aggregates
taken for the preparation of the specimen may be suitably altered to
obtain a compacted thickness of 63.5 mm. Vary the bitumen content
in the next trial by +0.50% and repeat the above procedure. Number
of trials are predetermined.
Properties of Mix:
The properties that are of interest include the theoretical speci c

gravity, Gt , the bulk speci c gravity of the mix Gm , percent air
voids Vv , percent volume of bitumen Vb , percent void in mixed
aggregate VMA and percent void lled with bitumen VFB. These
calculations will be discussed next, To understand these calculation a
phase diagram is given in the following gure, Figure-02,
Figure-02: Phase Diagram for Properties of Mix
Theoretical Speci c Gravity of the mix, Gt :
Theoretical speci c gravity Gt is the speci c gravity without

considering air voids, and is given by as follows,
Where,
W1 = Weight of Coarse Aggregates in the total mix,
W2 = Weight of Fine Aggregates in the total mix,
W3 = Weight of Filler in the total mix,
Wb = Weight of Bitumen in the total mix,
G1 = Apparent Speci c Gravity of Coarse Aggregates,
G2 = Apparent Speci c Gravity of Fine Aggregates,
G3 = Apparent Speci c Gravity of Filler,
Gb = Apparent Speci c Gravity of Bitumen,
Bulk Speci c Gravity of mix GM :
The Bulk Speci c Gravity or the actual speci c gravity of the mix GM is
the speci c gravity considering air voids and is found out by,
Where,
WM = Weight of mix in the air,
WW = Weight of mix in water,
The term (WM -WW) will indicate the volume of the mix.Sometimes to

get accurate Bulk Speci c Gravity, the specimen is coated with thin
lm of para n wax, when weight is taken in the water.
Air Void Percent VV :
Air Void VV is the percent of air voids by volume in the specimen and
is given by,
Where,
Gt = Theoretical Speci c Gravity of the mix,
GM = Bulk or Actual Speci c Gravity of the mix,
Percent Volume of Bitumen Vb :
The volume of bitumen Vb is the percent of volume of bitumen to the

total volume and given by as follows,
Where,
W1 = Weight of Coarse Aggregates in the total mix,
W2 = Weight of Fine Aggregates in the total mix,
W3 = Weight of Filler in the total mix,
Wb = Weight of Bitumen in the total mix,
Gb = Apparent Speci c Gravity of Bitumen,
GM = Bulk or Actual Speci c Gravity of the mix,
Voids in Mineral Aggregate, VMA :
Voids in mineral aggregate VMA is the volume of voids in the

aggregates, and is the sum of air voids and volume of bitumen and is
calculated from,
VMA = VV + Vb ,

Where,VV = percent air voids in the mix,Vb = percent bitumen content
in the mix,
Voids Filled with Asphalt, VFA :
Void lled with bitumen VFA is the voids in the mineral aggregate
frame work lled with the bitumen and is calculated as,
VFA = (Vb * 100)/VMA ,
Where,Vb = percent bitumen content in the mix,VMA = percent voids
in the mineral aggregate,
Determine Marshall Stability and

Flow:
Marshall Stability of a test specimen is the maximum load required to
produce failure when the specimen is preheated to a prescribed
temperature placed in a special test head and the load is applied at a
constant strain (5 cm per minute). While the stability test is in
progress dial gauge is used to measure the vertical deformation of
the specimen. The deformation at the failure point expressed in units
of 0.25 mm is called the Marshall Flow Value of the Specimen.
Design Graphs for Marshall Mix

Design:
There are 06 (Six) Graphs for Marshall Mix Design which is known as
“Design Graphs for Marshall Mix Design”.
——Asphalt Content vs. Air Void,

——Asphalt Content vs. Voids in Mineral Aggregate, VMA,
——Asphalt Content vs. Voids Filled with Asphalt, VFA,
——Asphalt Content vs. Unit Weight,
——Asphalt Content vs. Stability,
——Asphalt Content vs. Flow 0.01 inch,
These above graphical diagram of Marshall Mix Design are shown as

follows at Figure-03,
Figure-03: Design Graphs for Marshall Mix Design
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9/28/2019 Marshall Mix Design

HOME ABOUT STRUCTURAL ENGINEERING GEOTECHNICAL ENGINEERING

TRANSPORTATION ENGINEERING ENVIRONMENTAL ENGINEERING

Marshall Mix Design SITE STATISTICS

 May 15, 2019  Admin  Uncategorized 0 Page views today : 7

Mix Design Method:

The objective of Mix Design Method is to determine the amount of

The desirable qualities of a bituminous paving mixture are

The properties of the bituminous mix including the density and

——Provide adequate volume for the binder to occupy,

A dense mixture may be obtained when this particle size distribution

For Fine Aggregates, Fuller’s Law can be expressed as follows,

For Coarse Aggregates, Fuller’s Law can be expressed as follows,

Pi = A*(Di/D max)nC * 100 + B

After selecting the aggregates and their gradation, proportioning of

—Trial and Error Procedure: Vary the proportion of materials until

Wet Mix Design:

The Wet Mix Design determines the Optimum Bitumen Content.

Marshall Mix Design:

The basic concepts of the Marshall Mix Design method were

Marshall method seeks to select the asphalt binder content at a

Marshall Method history:

WES continued to re ne the Marshall Method through the 1950’s with

Marshall Mix Design Procedure:

The Marshall Mix Design Method consists of 6 basic steps:

5. Density and Voids Calculations,

Classi cation of Bitumen:

Classi cation of Bitumen can be speci ed as follows at Figure-01,

Figure-01: Classi cation of Bitumen

When volatile solvents are mixed with asphalt cement to make a

A mixture of asphalt cement, water and an emulsifying agent.

b) Cationic Emulsion (CIs): Cationic Emulsion are e ective in coating

————The Marshall stability and ow test provides the

Approximately 1200 gm of aggregates and ller is heated to a

The properties that are of interest include the theoretical speci c

Figure-02: Phase Diagram for Properties of Mix

Theoretical Speci c Gravity of the mix, Gt :

Theoretical speci c gravity Gt is the speci c gravity without

Bulk Speci c Gravity of mix GM :

The term (WM -WW) will indicate the volume of the mix.Sometimes to

Air Void Percent VV :

Percent Volume of Bitumen Vb :

The volume of bitumen Vb is the percent of volume of bitumen to the

Voids in Mineral Aggregate, VMA :

Voids in mineral aggregate VMA is the volume of voids in the

VMA = VV + Vb ,

Voids Filled with Asphalt, VFA :

Determine Marshall Stability and

Design Graphs for Marshall Mix

——Asphalt Content vs. Air Void,

These above graphical diagram of Marshall Mix Design are shown as

Figure-03: Design Graphs for Marshall Mix Design

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Pi = A(Di/D max)nC 100 + B